SICK VMS4200/VMS5200 Operating instructions

OPERATING INSTRUCTIONS

VMS4200/VMS5200 (Multicontroller)

Track and trace systems

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Product described

VMS4200/5200 (Multicontroller)

Document No.

8022965-17I6

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

www.sick.com

Legal notes

This work is protected by copyright. The associated rights are reserved by SICK AG.

Reproduction of this document or parts of this document is only permissible within

the limits of the legal provisions of copyright law. Any modification, abridgment, or

translation of this document is prohibited without the express written permission

of SICK AG.

The trademarks mentioned in this document are the property of their respective

owners.

Original documents

This document is an original document from SICK AG.

CONTENTS

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Contents

1 About this document......................................................................................................6

1.1 Limitation of liability ............................................................................................. 6

1.2 Purpose of this document .................................................................................... 6

1.3 Target groups ........................................................................................................ 6

1.4 Further information .............................................................................................. 7

1.5 Other relevant technical documentation/information ....................................... 7

1.6 Document conventions ........................................................................................ 7

2 Safety information .........................................................................................................8

2.1 Intended use ......................................................................................................... 8

2.2 General safety notes ............................................................................................ 9

2.3 Requirements for the qualification of personnel ............................................... 9

2.4 Sources of hazard ............................................................................................. 10

2.5 Protective devices ............................................................................................. 10

2.6 Warranty ............................................................................................................ 10

2.7 RoHS Directive ................................................................................................... 11

2.8 Safety conventions ............................................................................................ 11

2.9 Warning symbols on the system components ................................................. 12

2.10 Mandatory symbols ........................................................................................... 12

3 System description ..................................................................................................... 13

3.1 Scope of delivery ............................................................................................... 13

3.2 System components ......................................................................................... 14

3.2.1 LMS4x21 2D LiDAR sensors ............................................................. 16

3.2.2 Incremental encoder .......................................................................... 17

3.2.3 Trigger photoelectric retro-reflective sensor (optional) .................... 17

3.2.4 Cabinet ............................................................................................... 18

3.2.5 Expanding the system with a reading station ................................... 21

3.3 Operating principle ............................................................................................ 22

3.3.1 Triggering the recording of measured values ................................... 22

3.3.2 Transport conditions .......................................................................... 24

3.3.3 Recording of measured values and data processing ...................... 25

3.3.4 Data output ........................................................................................ 27

3.4 Additional functions .......................................................................................... 29

3.5 Nominal operating conditions .......................................................................... 30

3.5.1 Fixed scale values .............................................................................. 30

3.5.2 Dynamic scale value switchover ....................................................... 32

3.6 Legal for trade operation .................................................................................. 35

3.6.1 Information labels .............................................................................. 35

3.6.2 Security seal ....................................................................................... 40

3.6.3 Alibi memory and firmware ................................................................ 47

3.6.4 LFT display .......................................................................................... 50

3.6.5 Test instructions for market surveillance ......................................... 54

3.7 System requirements for legal for trade operation ......................................... 58

3.7.1 Requirements on the ambient conditions ........................................ 58

3.7.2 Requirements on the conveying equipment..................................... 58

3.7.3 Mounting requirements ..................................................................... 60

3.7.4 Object requirements .......................................................................... 62

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4 Mounting ...................................................................................................................... 64

4.1 Mounting 2D LiDAR sensors .............................................................................64

4.1.1 Overview ..............................................................................................64

4.1.2 Assembling the profiles of the telescopic tube .................................65

4.1.3 Mounting telescopic tube to the frame .............................................66

4.1.4 Fastening the 2D LiDAR sensors to the mounting plates ................66

4.2 Mounting the incremental encoder ..................................................................67

4.3 Mounting the trigger photoelectric retro-reflective sensor ..............................67

4.4 Mounting the cabinet .........................................................................................68

5 Electrical installation .................................................................................................. 69

5.1 Connection overview ..........................................................................................70

5.1.1 VMS4200/5200 .................................................................................70

5.1.2 VMS4200/5200 (Multicontroller) .....................................................71

5.2 Connection to the voltage supply ......................................................................72

5.2.1 VMS4200/5200 .................................................................................72

5.2.2 VMS4200/5200 (Multicontroller) .....................................................73

5.3 Connection for the Ethernet switch (set up at the factory) ..............................74

5.3.1 VMS4200/5200 .................................................................................74

5.3.2 VMS4200/5200 (Multicontroller) .....................................................75

5.4 Connection for the SIM2000 system controller - SIM2000

dimensioning controller CAN connection (set up at the factory) .....................76

5.5 Connection of 2D LiDAR sensors ......................................................................77

5.6 Connection for the LFT display (set up at the factory) .....................................79

5.7 Connecting the incremental encoder ...............................................................80

5.8 Connection for the photoelectric retro-reflective sensor (optional) ................81

5.9 Connection for the customer interface .............................................................82

6 Commissioning ............................................................................................................ 83

6.1 Switching on the system ....................................................................................83

6.2 Configuring the system with SOPAS ..................................................................84

6.2.1 Connecting the configuration PC .......................................................84

6.2.2 Installing SOPAS .................................................................................85

6.2.3 Assigning IP addresses .......................................................................86

6.2.4 Opening the configuration interface ..................................................93

6.2.5 Logging into the device .......................................................................94

6.2.6 Saving the parameters permanently .................................................95

7 Maintenance and repair .............................................................................................. 96

7.1 Monitoring and cleaning work ...........................................................................97

7.1.1 Control measurements .......................................................................97

7.1.2 Visual control ......................................................................................97

7.1.3 Cleaning the 2D LiDAR sensors .........................................................98

7.1.4 Cleaning the deflector mirror .............................................................99

7.1.5 Checking the incremental encoder components ........................... 100

7.1.6 Cleaning the photoelectric retro-reflective sensor ......................... 100

7.1.7 Cleaning the cabinet ........................................................................ 101

7.2 Replacing components ................................................................................... 102

7.2.1 Replacing the 2D LiDAR sensor ...................................................... 102

7.2.2 Replacing the deflector mirror ........................................................ 104

7.2.3 Replacing the incremental encoder components .......................... 105

7.2.4 Replacing the photoelectric retro-reflective sensor ....................... 106

CONTENTS

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8 Fault diagnosis .......................................................................................................... 107

8.1 Fault indications of the components ............................................................. 107

8.1.1 Fault indication on the LMS4x21 .................................................... 107

8.1.2 SIM2000 fault indication ................................................................. 108

8.1.3 Fault indication on the trigger photoelectric retro-reflective

sensor ............................................................................................... 109

8.2 Checks on the SIM2000 ................................................................................. 110

8.2.1 Checking the triggering .................................................................... 110

8.2.2 Checking the incremental encoder ................................................. 111

8.2.3 Checking the CAN cabling ............................................................... 112

8.3 Detailed fault analysis .................................................................................... 113

9 Technical data ........................................................................................................... 114

9.1 Data sheet ....................................................................................................... 114

9.2 Dimensional drawings ..................................................................................... 116

9.2.1 Dimensional drawings for the 2D LiDAR sensor ............................ 116

9.2.2 Dimensional drawings for the cabinet ............................................ 117

9.3 Compliance with EU directives ....................................................................... 118

10 Disposal ..................................................................................................................... 119

1 ABOUT THIS DOCUMENT

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1 About this document

This document about the VMS4200/5200 multi-dimensional measurement system

(Multicontroller):

• contains information that is required during the life cycle of the system.

• must be made available to all those who work with the system.

• should be read through carefully, and the contents fully understood before working

with the system.

1.1 Limitation of liability

Applicable standards and regulations, the latest technological developments, and our

many years of knowledge and experience have all been taken into account when

assembling the data and information contained in this document.

The manufacturer accepts no liability for damage caused by:

• Failure to observe this document.

• Non-compliance with notes and regulations.

• Unauthorized mounting and installation.

• Unauthorized technical and other changes.

• Use of unauthorized spare parts, wear and tear parts, and accessories.

• Unauthorized changes, adjustments, and/or manipulations of software.

• Failure to perform and document regular maintenance work.

The actual scope of delivery may differ from the features and illustrations shown here

where special variants are involved, if optional extras have been ordered, or as a result

of the latest technical changes.

1.2 Purpose of this document

This document describes the VMS4200/5200 multi-dimensional measurement system

(Multicontroller).

1.3 Target groups

This document is intended for qualified persons who operate the VMS4200/5200

(Multicontroller).

ABOUT THIS DOCUMENT 1

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1.4 Further information

Special local conditions

The local laws, regulations, technical rules and internal company operating instructions

at the usage site must be observed.

Storage of documents

This document and other relevant technical documentation/information:

• Must be kept available for reference.

• Must be handed over to new system operators/new specialist personnel.

1.5 Other relevant technical documentation/information

• Technical system documentation

– E207311 (EPLAN) - VMS5200-x MID

– E264664 (EPLAN) - VMS5200-x MID (Multicontroller)

Technical data

Connection diagram

Terminal diagram

• Operating instructions for the following system components:

Component Manufacturer

LMS4000 2D LiDAR sensor operating instructions SICK

SIM2000ST Sensor Integration Machine operating

instructions

SICK

SIC2000 Sensor Integration Cabinet operating instructions SICK

1.6 Document conventions

 Required tools

▸

Instructions

 Result of action

Reference to another document.

All measurement units used in this document are metric.

Subject to change without notice.

Illustrations may differ from the actual design.

2 SAFETY INFORMATION

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2 Safety information

2.1 Intended use

The VMS4200/5200 multi-dimensional measurement system (Multicontroller) is used

to measure cubic and irregularly-shaped objects on flat conveying systems in industrial

environments. The objects to be measured must be dimensionally stable, opaque, and

non-reflective.

The two 2D LMS4x21 LiDAR sensors are mounted horizontally above the conveying

technology and typically rotated at an angle of 45°.

The VMS4200/5200 (Multicontroller) determines the length, width and height. These

dimensional values can be used to calculate the volume of the smallest rectangular box

that fully encloses the object.

The measurement results can be transferred to the customer network via the data

interface of the SIM2000 system controller.

The VMS5200 multi-dimensional measurement system (Multicontroller) can be verified

as legal for trade and, after a successful MID conformity assessment, used for billing

purposes.

NOTE! Intended use also includes observance of this system description, in particular the

safety notes and repair and maintenance requirements as well as proper installation, in

particular for billing operation.

SAFETY INFORMATION 2

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2.2 General safety notes

▸

Please read this document through carefully and observe all the safety notes and

information before working on the multi-dimensional measurement system.

▸

Only qualified persons from the relevant departments are permitted to work on

the multi-dimensional measurement system.

▸

Follow operating processes.

▸

Follow local regulations.

▸

Follow all local regulations relating to working with electrical components.

• Only authorized persons are permitted access to the multi-dimensional measurement

system.

System damage/transport damage

Damage to the individual components can lead to malfunctions of the system as a whole.

▸

Do not ignore any damage caused to system components during transport.

▸

In case of damage, contact SICK Service.

2.3 Requirements for the qualification of personnel

Only qualified persons with the relevant technical expertise are permitted to work on the

system.

• Qualified persons have the specialist training, skills, and experience, as well as

knowledge of the relevant regulations and standards, to be able to perform work

assigned to them and to identify and avoid any potential dangers independently.

• Electricians have the professional training, skills and experience, and knowledge of

the relevant standards and provisions to work on electrical systems and to detect and

avoid any potential dangers independently.

2 SAFETY INFORMATION

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2.4 Sources of hazard

Laser class 2 can cause serious eye injuries if the following points are not observed:

▸

Never look directly into the laser beam.

▸

Never point the laser beam at people’s eyes.

▸

During commissioning or maintenance work, suitable eye protection must be worn.

▸

Do not open the housing.

▸

Current national regulations regarding laser protection must be observed.

Touching live devices, which may still be energized, can lead to death, burns or electrical

shock.

▸

Electrical work may only be performed on the system by qualified specialist personnel.

▸

Before working on electrical components, observe the five safety rules:

▸

Disconnect.

▸

Secure against being switched back on.

▸

Ensure that there is no voltage.

▸

Ground and short-circuit.

▸

Cover or enclose live parts in the vicinity.

▸

Never enter the area under suspended loads.

▸

Pay close attention when lifting loads.

▸

Comply with lifting instructions to prevent injuries and accidents.

▸

Use suitable, undamaged lifting tools.

▸

Wear personal protective equipment (safety helmet, safety shoes).

2.5 Protective devices

The multi-dimensional measurement system is designed in a way that allows for safe

operation. Protective devices reduce potential risks to the maximum possible extent.

• Laser protective cover for the 2D LMS4x21 LiDAR sensor

2.6 Warranty

No warranty claims will be accepted if:

▸

The safety notes and measures in this document are not observed.

▸

Parts or components of the multi-dimensional measurement system have been

installed, mounted or modified without authorization.

▸

The multi-dimensional measurement system has been altered or modified.

▸

The software has been modified, customized, and/or tampered with without

authorization.

Optical radiation:

Laser class 2

Electrical voltage

Suspended loads

SAFETY INFORMATION 2

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2.7 RoHS Directive

This product has been designed for specific applications in large industrial plants

according to Article 2 (4) e, RoHS 2011/65 / EU, and must therefore only be used in

such plants.

The product is neither suitable nor approved for use outside of these plants. SICK

therefore cannot provide any warranty or accept any liability whatsoever for such use.

2.8 Safety conventions

The warnings used in this manual have the following meanings:

DANGER

Identifies an imminent danger, which will lead to death or serious injuries if not

prevented.

WARNING

Identifies a situation presenting danger, which will lead to death or serious injuries

if not prevented.

CAUTION

Identifies a situation presenting danger, which may lead to minor or moderate

injuries if not prevented.

WARNING

Identifies a situation that may lead to property damage to the system or products in its

vicinity if not observed.

Note

Important information and useful tips.

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2.9 Warning symbols on the system components

Warning labels must not be removed or covered up. If labels are missing, these must be

affixed. Damaged labels must be replaced.

Symbol Meaning

Hazardous point warning

Hazardous electrical voltage warning

Laser beam warning

Suspended load warning

2.10 Mandatory symbols

Symbol Meaning

Read document

Use head protection

Use foot protection

Disconnect before maintenance or repairs

SYSTEM DESCRIPTION 3

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3 System description

3.1 Scope of delivery

NOTE!

▸

After delivery, inspect the system for transport damage and report any such damage

immediately.

▸

Check that the delivery includes all components listed on the delivery note.

System components

• 2 LMS4421R-16000 2D LiDAR sensors with laser protective cover for the VMS4200

(Multicontroller) or

2 LMS4521R-16000 2D LiDAR sensors with laser protective cover for the VMS5200

(Multicontroller)

• 1 LFT display - VMS5200 (Multicontroller) only

• 1 SIC2000 cabinet with a SIM2000 system controller, power supply unit module, and

Ethernet switch

• 1 incremental encoder with mounting kit (e.g., DFV60, DBS36)

• 1 modular mounting set

• 2 beam blockers

• Connecting cables

Optional

• 1 photoelectric retro-reflective sensor for triggered systems (e.g., RAY26)

• 1 cabinet of the VMS4200/5200 (Multicontroller) with a SIM2000 system controller

and a separate SIM2000 dimensioning controller. This increases the computing power

of the system, thereby allowing a higher throughout as well as enabling complex

identification solutions to be implemented.

• 1 deflector mirror for reducing the mounting height of the 2D LiDAR sensors

3 SYSTEM DESCRIPTION

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3.2 System components

Fig. 1: Components of the VMS4200/5200(Multicontroller)

Legend

1 LMS4x21 2D LiDAR sensors with laser protective cover

2 LFT display - VMS5200 (Multicontroller) only

3 Incremental encoder (e.g., DFV60)

4 Photoelectric retro-reflective sensor for triggered systems (e.g., RAY26)

5 Cabinet with the SIM2000 system controller (and possibly SIM2000

dimensioning controller) and power supply units

• Mount the system components according to the technical drawing on a frame provided

by the customer.

• Additional glare protection on the frame (beam blocker) prevents objects located

outside of the measuring range from being included in the calculation of measured

values.

Devices

Mounting

SYSTEM DESCRIPTION 3

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Fig. 2: VMS4200/5200 (Multicontroller) with deflector mirror

Legend

1 LMS4x21 2D LiDAR sensors with laser protective cover

2 Deflector mirror

• If the 2D LiDAR sensors cannot be mounted at the prescribed minimum height, the

measurement points can be captured by a deflector mirror mounted parallel to the

2D LiDAR sensors.

• The resulting extension of the light path means that you can save space when

mounting the 2D LiDAR sensor on the conveying equipment.

• The deflection via the mirror is free of loss thanks to its special surface metallization,

as this rules out light refraction.

• The upper figure shows a visualization example of the arrangement of the 2D LiDAR

sensors and the deflector mirror over the transport belt.

• Other system constructions and the operating principle of the VMS4200/5200

(Multicontroller) correspond to the specifications of the type examination certificate.

NOTE! These operating instructions describe system variant without deflector mirror.

System variant

with deflector mirror

3 SYSTEM DESCRIPTION

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3.2.1 LMS4x21 2D LiDAR sensors

Fig. 3: LMS4x21 2D LiDAR sensors with LFT display - VMS5200 (Multicontroller) only

Legend

1 LMS4x21 2D-LiDAR sensor

2 Laser protective cover

3 LFT display for billing-capable VMS5200 (Multicontroller) measurement

systems

• Consists of two 2D LMS4x21 LiDAR sensors with laser protective covers that

are mounted on a profile and located on the right and left above the conveyor.

• The LMS4x21 2D LiDAR sensors are configured as master and slave.

• Used to calculate the relevant object dimensions by detecting the object on flat

conveying systems without making contact.

• VMS5200 measurement systems (Multicontroller) operating in legal for trade

applications also have a separate LFT display to show the measurement results,

status information, firmware version, and the logbook (version history).

Features

Function

LFT display

SYSTEM DESCRIPTION 3

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3.2.2 Incremental encoder

Fig. 4: DFV60 incremental encoder

Legend

1 Measuring wheel

2 Spring-loaded mounting arm

• Measuring wheel system mounted under the conveyor belt.

• Large spring travel and pivot range of the spring arm compensates for unevenness

on measurement surface.

• Measurement of linear movements.

• Detection of position and speed directly on the running surface of the conveyor belt

using a precision measuring wheel.

3.2.3 Trigger photoelectric retro-reflective sensor (optional)

Fig. 5: Trigger photoelectric retro-reflective sensor and reflector

Legend

1 Photoelectric retro-reflective sensor (e.g., RAY26)

2 Reflector

• The light band emitted by the object detection photoelectric sensor is reflected back

by a reflector.

• Sender and receiver are arranged parallel to one another in the housing.

• Mounted in front of the measuring field.

• Supplies the trigger signal in systems with triggered measurement.

• The trigger signal activates the sensors and opens the internal reading gate.

• The photoelectric retro-reflective sensor trigger is available as an option.

Properties

Function

Features

Function

3 SYSTEM DESCRIPTION

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3.2.4 Cabinet

Fig. 6: Cabinet of the VMS4200/5200

Legend

1 Air inlet for cooling (with filter mat and cooler)

2 SIM2000 system controller with alibi memory

3 Power supply unit for supplying voltage to the LFT display

4 Terminals for voltage supply IN (100–264 V AC / 50–60 Hz)

5 Air outlet for cooling (with filter mat)

6 Power supply unit for supplying voltage to the SIM2000 and 2D LiDAR

sensors

7 Terminals (24 V DC) and fuse module OUT

8 Ethernet switch for connecting the system components

• Contains power supply units for the central voltage supply to system components.

• Contains the SIM2000 system controller, the central processing unit, and the control

unit of the VMS4200/5200.

• The SIM2000 system controller contains the legally relevant memory (alibi memory).

• Central power supply for all system components.

• Coordinates all connected sensors and processes the measured values received.

• The SIM2000 system controller receives the measuring points from the 2D LiDAR

sensors and uses the 2D sections to calculate a three-dimensional model.

• Determines the box volume and dimensional values based on the calculated 3D model.

• The data is sent to the higher-level customer system via the system controller in a host

telegram with a defined format.

NOTE! In the case of the VMS5200, the measurement results are saved in the

SIM2000 alibi memory, which is required for legal-for-trade verification.

Cabinet of the

VMS4200/5200

Properties

Function

SYSTEM DESCRIPTION 3

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Fig. 7: Cabinet for VMS4200/5200 (Multicontroller)

Legend

1 Terminals for voltage supply IN (100–264 V AC / 50–60 Hz)

2 Air inlet for cooling (with filter mat and cooler)

3 Terminals (24 V DC) and fuse module OUT

4 SIM2000 system controller with alibi memory

5 Power supply unit for supplying voltage to the SIM2000 and 2D LiDAR

sensors

6 Air outlet for cooling (with filter mat)

7 Air outlet for cooling (with filter mat)

8 Power supply unit for supplying voltage to the LFT display

9 SIM2000 dimensioning controller

10 Ethernet switch for connecting the system components

11 Air inlet for cooling (with filter mat and cooler)

12 Ethernet switch for connecting external scanners.

Cabinet of the

VMS4200/5200

(Multicontroller)

3 SYSTEM DESCRIPTION

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• In addition to the SIM2000 system controller, the cabinet of the VMS4200/5200

(Multicontroller) system variant also contains a separate SIM2000 dimensioning

controller.

• This increases the computing power of the system, thereby allowing a higher

throughout as well as enabling complex identification solutions to be implemented.

• The dimensioning controller receives the measuring points from the LMS4x21 2D

LiDAR sensors and uses the 2D sections to calculate a three-dimensional model.

• Based on this calculated 3D model, the dimensioning controller determines the

dimensional values and transmits the measurement results to the SIM2000 system

controller via CAN bus. These dimensions can be used to calculate the so-called box

volume.

• The data is sent to the higher-level customer system via the system controller in a host

telegram with a defined format.

NOTE! In the case of the VMS5200 (Multicontroller), the measurement results are

saved in the SIM2000 alibi memory, which is required for legal-for-trade verification.

SIM2000

dimensioning controller

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